3D LiDAR Scanning at Tomago – Reducing Shutdown Risks in Aluminium Processing Plants

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Supporting Industrial Maintenance, Plant Modifications and Mechanical Engineering in Tomago, NSW

Industrial facilities in Tomago, near Newcastle in New South Wales, operate with complex mechanical equipment, structural steelwork, pipework, conveyors and processing infrastructure.

For aluminium smelting and associated manufacturing operations, maintaining accurate information about existing plant conditions is essential when planning equipment upgrades, replacement components and maintenance shutdowns.




Hamilton By Design provides 3D LiDAR scanning, point cloud modelling and mechanical engineering services to support industrial facilities throughout Tomago, Newcastle and the Hunter Region.

Why Accurate Plant Measurements Matter

Industrial plant modifications can be challenging when existing drawings are outdated, incomplete or do not reflect changes made during previous maintenance activities.

Traditional site measurements may also miss important details, particularly around congested pipework, structural connections and equipment interfaces.

These uncertainties can result in:

  • Replacement components that do not fit correctly.

  • Unexpected clashes with existing structures or equipment.

  • Additional fabrication and rework.

  • Extended installation and maintenance shutdowns.

  • Increased project costs and construction delays.

3D LiDAR scanning helps reduce these risks by capturing the existing plant geometry before detailed engineering and fabrication begin.

How 3D LiDAR Scanning Supports Aluminium Processing Facilities

Using terrestrial laser scanning technology, Hamilton By Design can capture detailed spatial information from existing industrial environments.

The resulting point cloud provides a three-dimensional reference for engineering and design activities.

Potential applications include:

1. Equipment Replacement and Upgrades

Capture existing equipment arrangements, mounting positions and surrounding structures before designing replacement machinery or components.

2. Pipework and Ductwork Modifications

Develop proposed pipework and ductwork arrangements within existing plant geometry to identify potential clashes and access restrictions.

3. Conveyor and Transfer Chute Design

Support conveyor modifications, transfer chute replacements and material-handling improvements using existing-condition measurements.

4. Structural and Mechanical Interfaces

Identify the position of supporting steelwork, platforms, equipment foundations


Explore Related Engineering Services

Hamilton By Design provides engineering-led 3D LiDAR scanning, mechanical engineering, CAD modelling and reverse engineering services for industrial facilities throughout Newcastle, Tomago, the Hunter Region and NSW. Explore our related engineering services below.

Explore More 3D Scanning & Engineering Articles

Explore related Hamilton By Design articles covering engineering-grade LiDAR scanning, point cloud modelling, SolidWorks design, mechanical engineering and fabrication planning. These topics support industrial plant upgrades, maintenance projects and shutdown risk reduction.

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